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Honeywell - Tata Chemicals Improves Data Accessibility with OneWireless

Tata was facing data accessibility challenges in the cement plant control room tapping signals from remote process control areas and other distant locations, including the gas scrubber. Tata needed a wireless solution to extend its control network securely to remote locations that would also provide seamless communication with existing control applications.

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  • SUPPLIER
  • Honeywell
    Honeywell invents and manufactures technologies to address some of the world’s toughest challenges initiated by revolutionary macrotrends in science, technology and society. They improves business performance for customers with automation and control solutions, equipment and services that enhance safety, reliability and efficiency. Year founded: 1906 Revenue: $40.3 billion (2014) NYSE: HON
  • INDUSTRIES
  • Chemicals
  • FUNCTIONS
  • Maintenance
  • CUSTOMER
  • Tata Chemicals is an Indian global company with interests in chemicals, crop nutrition and consumer products. The company is one of the largest chemical companies in India with significant operations in India and Africa, with more than 4,700 employees.

  • CONNECTIVITY PROTOCOLS
  • SOLUTION
  • Honeywell’s OneWireless network is an industrial wireless mesh network that extends the process control network into the field to deliver applications that improve plant efficiency, reliability and safety. The wireless mesh network is formed with industrial wireless nodes, called multinodes, that self-discover to create an industrial mesh network within seconds. Hardware Components - wireless transmitter - gateway with SMPS - Lantronix converter - serial interface card - FTA communication assembly Software Components - Experion Process Knowledge System (PKS) - OneWireless network

  • DATA COLLECTED
  • Communication Performance, Connectivity Status, Device Diagnostic Status, Network Coverage
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Mature (technology has been on the market for > 5 years)
  • OPERATIONAL IMPACT
  • Impact #1
    [Data Management - Data Analysis]
    Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
    Impact #2
    [Efficiency Improvement - Maintenance]
    Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
    Impact #3
    [Cost Reduction - Labor]
    Total cost of ownership is lowered due to reduction in labor cost and IT management.
  • QUANTITATIVE BENEFIT
  • USE CASES
  • Process Control & Optimization (PCO)
    Process Control and Optimization (PCO) is the discipline of adjusting a process to maintain or optimize a specified set of parameters without violating process constraints.The PCO market is being driven by rising demand for energy efficient production processes, safety and security concerns, and the development of IoT systems that can reliably predict process deviations.Fundamentally, there are three parameters that can be adjusted to affect optimal performance:- Equipment optimizationThe first step is to verify that the existing equipment is being used to its fullest advantage by examining operating data to identify equipment bottlenecks.- Operating proceduresOperating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant in manual.- Control optimizationIn a typical processing plant, such as a chemical plant or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow. If the control loop is not properly designed and tuned, the process runs below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely. For each control loop to run optimally, identification of sensor, valve, and tuning problems is important. It has been well documented that over 35% of control loops typically have problems. The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.
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